Method for operating a plasma arc torch having multiple operating modes

ABSTRACT

The present invention provides a multi-mode plasma arc torch that includes a cylindrical vessel having a first end and a second end, a first tangential inlet/outlet connected to or proximate to the first end, a second tangential inlet/outlet connected to or proximate to the second end, an electrode housing connected to the first end of the cylindrical vessel such that a first electrode is (a) aligned with a longitudinal axis of the cylindrical vessel, and (b) extends into the cylindrical vessel, and a hollow electrode nozzle connected to the second end of the cylindrical vessel such that the center line of the hollow electrode nozzle is aligned with the longitudinal axis of the cylindrical vessel. Adjusting a position of the electrode with respect to the hollow electrode causes the multi-mode plasma arc torch to operate in a dead short resistive mode, a submerged arc mode, an electrolysis mode, a glow discharge mode or a plasma arc mode.

PRIORITY CLAIM AND CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation application of U.S. patentapplication Ser. No. 13/633,128 filed on Oct. 1, 2012, now U.S. Pat. No.8,810,122, and entitled “Plasma Arc Torch Having Multiple OperatingModes”, which is a continuation-in-part application of U.S. patentapplication Ser. No. 12/371,575 filed on Feb. 13, 2009, now U.S. Pat.No. 8,278,810, and entitled “Solid Oxide High Temperature ElectrolysisGlow Discharge”, which is (a) a continuation-in-part application of U.S.patent application Ser. No. 12/288,170 filed on Oct. 16, 2008 andentitled “System, Method And Apparatus for Creating an Electric GlowDischarge”, which is a non-provisional application of U.S. provisionalpatent application 60/980,443 filed on Oct. 16, 2007 and entitled“System, Method and Apparatus for Carbonizing Oil Shale withElectrolysis Plasma Well Screen”; (b) a continuation-in-part applicationof U.S. patent application Ser. No. 12/370,591 filed on Feb. 12, 2009,now U.S. Pat. No. 8,074,439, and entitled “System, Method and Apparatusfor Lean Combustion with Plasma from an Electrical Arc”, which isnon-provisional patent application of U.S. provisional patentapplication Ser. No. 61/027,879 filed on Feb. 12, 2008 and entitled,“System, Method and Apparatus for Lean Combustion with Plasma from anElectrical Arc”; and (c) a non-provisional patent application of U.S.provisional patent application 61/028,386 filed on Feb. 13, 2008 andentitled “High Temperature Plasma Electrolysis Reactor Configured as anEvaporator, Filter, Heater or Torch.” All of the foregoing applicationsare hereby incorporated by reference in their entirety.

This application is also related to U.S. Pat. No. 7,422,695 and U.S.Pat. No. 7,857,972 and multiple patents and patent application thatclaim priority thereto.

FIELD OF THE INVENTION

The present invention relates generally to solid oxide electrolysiscells and plasma torches. More specifically, the present inventionrelates to a method for operating plasma torch having multiple operatingmodes.

BACKGROUND OF THE INVENTION

Glow discharge and plasma systems are becoming every more present withthe emphasis on renewable fuels, pollution prevention, clean water andmore efficient processing methods. Glow discharge is also referred to aselectro-plasma, plasma electrolysis and high temperature electrolysis.In liquid glow discharge systems a plasma sheath is formed around thecathode located within an electrolysis cell.

U.S. Pat. No. 6,228,266 discloses a water treatment apparatus using aplasma reactor and a method of water treatment. The apparatus includes ahousing having a polluted water inlet and a polluted water outlet; aplurality of beads (e.g., nylon and other plastic type beads) filledinto the interior of the housing; a pair of electrodes, one of theelectrodes contacting with the bottom of the housing, another of theelectrodes contacting an upper portion of the uppermost beads; and apulse generator connected with the electrodes by a power cable forgenerating pulses. Some drawbacks of the '266 plasma reactor are therequirements of an extremely high voltage pulse generator (30 KW to 150KW), a plurality of various beads in a web shape and operating thereactor full from top to bottom. Likewise, the plasma reactor is notdesigned for separating a gas from the bulk liquid, nor can it recoverheat or generate hydrogen. In fact, the addition of air to the plasmareactor completely defeats the sole purpose of current research forgenerating hydrogen via electrolysis or plasma or a combination of both.If any hydrogen is generated within the plasma reactor, the addition ofair will cause the hydrogen to react with oxygen and form water. Also,there is no mention of any means for generating heat by cooling thecathode. Likewise, there is no mention of cooking organics unto thebeads, nor the ability to reboil and concentrate liquids (e.g., spentacids, black liquor, etc.), nor recovering caustic and sulfides fromblack liquor.

The following is a list of prior art similar to the '266 patent:

Pat. No. Title 481,979 Apparatus for electrically purifying water501,732 Method of an apparatus for purifying water 3,798,784 Process andapparatus for the treatment of moist materials 4,265,747 Disinfectionand purification of fluids using focused laser radiation 4,624,765Separation of dispersed liquid phase from continuous fluid phase5,019,268 Method and apparatus for purifying waste water 5,048,404 Highpulsed voltage systems for extending the shelf life of pumpable foodproducts 5,326,530 High pulsed voltage systems for extending the shelflife of pumpable food products 5,348,629 Method and apparatus forelectrolytic processing of materials 5,368,724 Apparatus for treating aconfined liquid by means of a pulse electrical discharge 5,655,210Corona source for producing corona discharge and fluid waste treatmentwith corona discharge 5,746,984 Exhaust system with emissions storagedevice and plasma reactor 5,879,555 Electrochemical treatment ofmaterials 6,007,681 Apparatus and method for treating exhaust gas andpulse generator used therefor

Plasma arc torches are commonly used by fabricators, machine shops,welders and semi-conductor plants for cutting, gouging, welding, plasmaspraying coatings and manufacturing wafers. The plasma torch is operatedin one of two modes—transferred arc or non-transferred arc. The mostcommon torch found in many welding shops in the transferred arc plasmatorch. It is operated very similar to a DC welder in that a groundingclamp is attached to a workpiece. The operator, usually a welder,depresses a trigger on the plasma torch handle which forms a pilot arcbetween a centrally located cathode and an anode nozzle. When theoperator brings the plasma torch pilot arc close to the workpiece thearc is transferred from the anode nozzle via the electrically conductiveplasma to the workpiece. Hence the name transferred arc. Thenon-transferred arc plasma torch retains the arc within the torch. Quitesimply the arc remains attached to the anode nozzle. This requirescooling the anode. Common non-transferred arc plasma torches have a heatrejection rate of 30%. In other words, 30% of the total torch power isrejected as heat.

A major drawback in using plasma torches is the cost of inert gases suchas argon and hydrogen. There have been several attempts for forming theworking or plasma gas within the torch itself by using rejected heatfrom the electrodes to generate steam from water. The objective is toincrease the total efficiency of the torch as well as reduce plasma gascost. However, there is not a single working example that can runcontinuous duty. For example, the Multiplaz torch (U.S. Pat. Nos.6,087,616 and 6,156,994) is a small hand held torch that must bemanually refilled with water. The Multiplaz torch is not a continuoususe plasma torch.

Other prior art plasma torches are disclosed in the following patents.

Pat. No. Title 3,567,898 Plasma cutting torch 3,830,428 Plasma torches4,311,897 Plasma arc torch and nozzle assembly 4,531,043 Method of andapparatus for stabilization of low-temperature plasma of an arc burner5,609,777 Electric-arc plasma steam torch 5,660,743 Plasma arc torchhaving water injection nozzle assembly

U.S. Pat. No. 4,791,268 discloses “an arc plasma torch includes amoveable cathode and a fixed anode which are automatically separated bythe buildup of gas pressure within the torch after a current flow isestablished between the cathode and the anode. The gas pressure draws anontransferred pilot arc to produce a plasma jet. The torch is thuscontact started, not through contact with an external workpiece, butthrough internal contact of the cathode and anode. Once the pilot arc isdrawn, the torch may be used in the nontransferred mode, or the arc maybe easily transferred to a workpiece. In a preferred embodiment, thecathode has a piston part which slidingly moves within a cylinder whensufficient gas pressure is supplied. In another embodiment, the torch isa hand-held unit and permits control of current and gas flow with asingle control.”

Typically, and as disclosed in the '268 patent, plasma torch gas flow isset upstream of the torch with a pressure regulator and flow regulator.In addition to transferred arc and non-transferred arc, plasma arctorches can be defined by arc starting method. The high voltage methodstarts by using a high voltage to jump the arc from the centered cathodeelectrode to the shield nozzle. The blow-back arc starting method issimilar to stick welding. For example, similar to a welder touching agrounded work-pieced then pulling back the electrode to form an arc, ablow-back torch uses the cutting gas to push the negative (−) cathodeelectrode away from the shield nozzle. Normally, in the blow-back torcha spring or compressed gas pushes the cathode towards the nozzle so thatit resets to the start mode when not in operation.

The '268 plasma torch is a blow-back type torch that uses the contactstarting method. Likewise, by depressing a button and/or trigger acurrent is allowed to flow through the torch and thus the torch is in adead-short mode. Immediately thereafter, gas flowing within a blow-backcontact starting torch pushes upon a piston to move the cathode awayfrom the anode thus forming an arc. Voltage is set based upon themaximum distance the cathode can be pushed back from the anode. Thereare no means for controlling voltage. Likewise, this type of torch canonly be operated in one mode—Plasma Arc. Backflowing material throughthe anode nozzle is not possible in the '268 plasma torch. Moreover,there is no disclosure of coupling this torch to a solid oxide glowdischarge cell.

U.S. Pat. No. 4,463,245 discloses “A plasma torch (40) comprises ahandle (41) having an upper end (41B) which houses the componentsforming a torch body (43). Body (33) incorporates a rod electrode (10)having an end which cooperates with an annular tip electrode (13) toform a spark gap. An ionizable fuel gas is fed to the spark gap via tube(44) within the handle (41), the gas from tube (44) flowing axiallyalong rod electrode (10) and being diverted radially through apertures(16) so as to impinge upon and act as a coolant for a thin-walledportion (14) of the annular tip electrode (13). With this arrangementthe heat generated by the electrical arc in the inter-electrode gap issubstantially confined to the annular tip portion (13A) of electrode(13) which is both consumable and replaceable in that portion (13A) issecured by screw threads to the adjoining portion (13B) of electrode(13) and which is integral with the thin-walled portion (14).” Onceagain there is no disclosure of coupling this torch to a solid oxideglow discharge cell.

The following is a list of prior art teachings with respect to startinga torch and modes of operation.

Pat. No. Title 2,784,294 Welding torch 2,898,441 Arc torch push starting2,923,809 Arc cutting of metals 3,004,189 Combination automatic-startingelectrical plasma torch and gas shutoff valve 3,082,314 Plasma arc torch3,131,288 Electric arc torch 3,242,305 Plasma retract arc torch3,534,388 Arc torch cutting process 3,619,549 Arc torch cutting process3,641,308 Plasma arc torch having liquid laminar flow jet for arcconstriction 3,787,247 Water-scrubber cutting table 3,833,787 Plasma jetcutting torch having reduced noise generating characteristics 4,203,022Method and apparatus for positioning a plasma arc cutting torch4,463,245 Plasma cutting and welding torches with improved nozzleelectrode cooling 4,567,346 Arc-striking method for a welding or cuttingtorch and a torch adapted to carry out said method

High temperature steam electrolysis and glow discharge are twotechnologies that are currently being viewed as the future for thehydrogen economy. Likewise, coal gasification is being viewed as thetechnology of choice for reducing carbon, sulfur dioxide and mercuryemissions from coal burning power plants. Renewables such as windturbines, hydroelectric and biomass are being exploited in order toreduce global warming.

Water is one of our most valuable resources. Copious amounts of waterare used in industrial processes with the end result of producingwastewater. Water treatment and wastewater treatment go hand in handwith the production of energy.

Therefore, a need exists for a plasma arc torch that can be operated inmultiple modes.

SUMMARY OF THE INVENTION

The present invention provides a multi-mode plasma arc torch thatincludes a cylindrical vessel having a first end and a second end, afirst tangential inlet/outlet connected to or proximate to the firstend, a second tangential inlet/outlet connected to or proximate to thesecond end, an electrode housing connected to the first end of thecylindrical vessel such that a first electrode is (a) aligned with alongitudinal axis of the cylindrical vessel, and (b) extends into thecylindrical vessel, and a hollow electrode nozzle connected to thesecond end of the cylindrical vessel such that the center line of thehollow electrode nozzle is aligned with the longitudinal axis of thecylindrical vessel. Adjusting a position of the electrode with respectto the hollow electrode causes the multi-mode plasma arc torch tooperate in a dead short resistive mode, a submerged arc mode, anelectrolysis mode, a glow discharge mode or a plasma arc mode.

In addition, the present invention provides a system that includes aplasma arc torch, a pump/compressor and three three-way valves. Themulti-mode plasma arc torch includes a cylindrical vessel having a firstend and a second end, a first tangential inlet/outlet connected to orproximate to the first end, a second tangential inlet/outlet connectedto or proximate to the second end, an electrode housing connected to thefirst end of the cylindrical vessel such that a first electrode is (a)aligned with a longitudinal axis of the cylindrical vessel, and (b)extends into the cylindrical vessel, and a hollow electrode nozzleconnected to the second end of the cylindrical vessel such that thecenter line of the hollow electrode nozzle is aligned with thelongitudinal axis of the cylindrical vessel. Adjusting a position of theelectrode with respect to the hollow electrode causes the multi-modeplasma arc torch to operate in a dead short resistive mode, a submergedarc mode, an electrolysis mode, a glow discharge mode or a plasma arcmode. A first three-way valve connected to the first tangentialinlet/outlet and a discharge of the pump/compressor. A second three-wayvalve connected to the second tangential inlet/outlet and a discharge ofthe pump/compressor. A third three-way valve connected to an exteriorend of the hollow electrode nozzle and a discharge of thepump/compressor.

The present invention also provides a method for operating the plasmaarc torch and plasma arc torch system in the five operating modes. Forexample, a method for operating a multi-mode plasma arc torch includesthe steps of: (1) providing the multi-mode plasma arc torch comprising acylindrical vessel having a first end and a second end, a firsttangential inlet/outlet connected to or proximate to the first end, asecond tangential inlet/outlet connected to or proximate to the secondend, an electrode housing connected to the first end of the cylindricalvessel such that a first electrode is (a) aligned with a longitudinalaxis of the cylindrical vessel, and (b) extends into the cylindricalvessel, and a hollow electrode nozzle connected to the second end of thecylindrical vessel such that a center line of the hollow electrodenozzle is aligned with the longitudinal axis of the cylindrical vessel,the hollow electrode having a first end disposed within the cylindricalvessel and a second end disposed outside the cylindrical vessel; and (2)operating the multi-mode plasma arc torch in a dead short resistivemode, a submerged arc mode, an electrolysis mode, a glow discharge modeor a plasma arc mode by adjusting a position of the first electrode withrespect to the hollow electrode.

Another method for operating a multi-mode plasma arc torch includes thesteps of: (1) providing a plasma arc torch comprising a cylindricalvessel having a first end and a second end, a first tangentialinlet/outlet connected to or proximate to the first end, a secondtangential inlet/outlet connected to or proximate to the second end, anelectrode housing connected to the first end of the cylindrical vesselsuch that a first electrode is (a) aligned with a longitudinal axis ofthe cylindrical vessel, and (b) extends into the cylindrical vessel, ahollow electrode nozzle connected to the second end of the cylindricalvessel such that a center line of the hollow electrode nozzle is alignedwith the longitudinal axis of the cylindrical vessel, the hollowelectrode nozzle having a first end disposed within the cylindricalvessel and a second end disposed outside the cylindrical vessel; (2)providing a pump/compressor; (3) providing a first three-way valveconnected to the first tangential inlet/outlet and a discharge of thepump/compressor; (4) providing a second three-way valve connected to thesecond tangential inlet/outlet and the discharge of the pump/compressor;(5) providing a third three-way valve connected to the second end of thehollow electrode nozzle and the discharge of the pump/compressor; and(6) operating the multi-mode plasma arc torch in a dead short resistivemode, a submerged arc mode, an electrolysis mode, a glow discharge modeor a plasma arc mode by adjusting a position of the first electrode withrespect to the hollow electrode.

Yet another method for operating a multi-mode plasma arc torch includesthe steps of: (1) providing the multi-mode plasma torch comprising acylindrical vessel having a first end and a second end, a firsttangential inlet/outlet connected to or proximate to the first end, asecond tangential inlet/outlet connected to or proximate to the secondend, an electrode housing connected to the first end of the cylindricalvessel, the electrode housing having a first electrode aligned with alongitudinal axis of the cylindrical vessel, extending into thecylindrical vessel, moveable along the longitudinal axis, andelectrically isolated from the cylindrical vessel, a hollow electrodenozzle connected to the second end of the cylindrical vessel such that acenter line of the hollow electrode nozzle is aligned with thelongitudinal axis of the cylindrical vessel, the hollow electrode nozzlehaving a first end disposed within the cylindrical vessel and a secondend disposed outside the cylindrical vessel, and a linear actuatoroperably connected to the first electrode to adjust a position of thefirst electrode with respect to the hollow electrode nozzle; and (2)operating the multi-mode plasma arc torch in a dead short resistivemode, a submerged arc mode, an electrolysis mode, a glow discharge modeor a plasma arc mode by adjusting the position of the first electrodewith respect to the hollow electrode nozzle using the linear actuator.

The present invention is described in detail below with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and further advantages of the invention may be betterunderstood by referring to the following description in conjunction withthe accompanying drawings, in which:

FIG. 1 is a diagram of a plasma arc torch in accordance with oneembodiment of the present invention;

FIG. 2 is a cross-sectional view comparing and contrasting a solid oxidecell to a liquid electrolyte cell in accordance with one embodiment ofthe present invention;

FIG. 3 is a graph showing an operating curve a glow discharge cell inaccordance with one embodiment of the present invention.

FIG. 4 is a cross-sectional view of a glow discharge cell in accordancewith one embodiment of the present invention;

FIG. 5 is a cross-sectional view of a glow discharge cell in accordancewith another embodiment of the present invention;

FIG. 6 is a cross-sectional view of a Solid Oxide Plasma Arc TorchSystem in accordance with another embodiment of the present invention;

FIG. 7 is a cross-sectional view of a Solid Oxide Plasma Arc TorchSystem in accordance with another embodiment of the present invention;

FIG. 8 is a cross-sectional view of a Solid Oxide Transferred Arc PlasmaTorch in accordance with another embodiment of the present invention;

FIG. 9 is a cross-sectional view of a Solid Oxide Non-Transferred ArcPlasma Torch in accordance with another embodiment of the presentinvention;

FIG. 10 is a table showing the results of the tailings pond water andsolids analysis treated with one embodiment of the present invention;

FIG. 11 is a cross-sectional view of a Multi-Mode Plasma Arc Torch inaccordance with another embodiment of the present invention;

FIG. 12 is illustrates the first electrode positions to operate aMulti-Mode Plasma Arc Torch in accordance with another embodiment of thepresent invention;

FIGS. 13A-13F are cross-sectional views of various shapes for the hollowelectrode nozzle in accordance with another embodiment of the presentinvention;

FIG. 14 is a cross-sectional view of dual first electrode configurationin accordance with another embodiment of the present invention;

FIG. 15 is a block diagram of a system for operating the Multi-ModePlasma Arc Torch in five different modes in accordance with anotherembodiment of the present invention;

FIG. 16 is a cross-sectional view of an anode nozzle flange mountedassembly for the Multi-Mode Plasma Arc Torch in accordance with anotherembodiment of the present invention;

FIG. 17 is a diagram of a Multi-Mode Plasma Arc Torch with variousattachment devices in accordance with another embodiment of the presentinvention;

FIG. 18 is a diagram of a Multi-Mode Plasma Arc Torch with variousattachment devices in accordance with another embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

While the making and using of various embodiments of the presentinvention are discussed in detail below, it should be appreciated thatthe present invention provides many applicable inventive concepts thatcan be embodied in a wide variety of specific contexts. The specificembodiments discussed herein are merely illustrative of specific ways tomake and use the invention and do not delimit the scope of theinvention.

Now referring to FIG. 1, a plasma arc torch 100 in accordance with oneembodiment of the present invention is shown. The plasma arc torch 100is a modified version of the ARCWHIRL® device disclosed in U.S. Pat. No.7,422,695 (which is hereby incorporated by reference in its entirety)that produces unexpected results. More specifically, by attaching adischarge volute 102 to the bottom of the vessel 104, closing off thevortex finder, replacing the bottom electrode with a hollow electrodenozzle 106, an electrical arc can be maintained while discharging plasma108 through the hollow electrode nozzle 106 regardless of how much gas(e.g., air), fluid (e.g., water) or steam 110 is injected into plasmaarc torch 100. In addition, when a valve (not shown) is connected to thedischarge volute 102, the mass flow of plasma 108 discharged from thehollow electrode nozzle 106 can be controlled by throttling the valve(not shown) while adjusting the position of the first electrode 112using the linear actuator 114.

As a result, plasma arc torch 100 includes a cylindrical vessel 104having a first end 116 and a second end 118. A tangential inlet 120 isconnected to or proximate to the first end 116 and a tangential outlet102 (discharge volute) is connected to or proximate to the second end118. An electrode housing 122 is connected to the first end 116 of thecylindrical vessel 104 such that a first electrode 112 is aligned withthe longitudinal axis 124 of the cylindrical vessel 104, extends intothe cylindrical vessel 104, and can be moved along the longitudinal axis124. Moreover, a linear actuator 114 is connected to the first electrode112 to adjust the position of the first electrode 112 within thecylindrical vessel 104 along the longitudinal axis of the cylindricalvessel 124 as indicated by arrows 126. The hollow electrode nozzle 106is connected to the second end 118 of the cylindrical vessel 104 suchthat the center line of the hollow electrode nozzle 106 is aligned withthe longitudinal axis 124 of the cylindrical vessel 104. The shape ofthe hollow portion 128 of the hollow electrode nozzle 106 can becylindrical or conical. Moreover, the hollow electrode nozzle 106 canextend to the second end 118 of the cylindrical vessel 104 or extendinto the cylindrical vessel 104 as shown. As shown in FIG. 1, thetangential inlet 120 is volute attached to the first end 116 of thecylindrical vessel 104, the tangential outlet 102 is a volute attachedto the second end 118 of the cylindrical vessel 104, the electrodehousing 122 is connected to the inlet volute 120, and the hollowelectrode nozzle 106 (cylindrical configuration) is connected to thedischarge volute 102. Note that the plasma arc torch 100 is not shown toscale.

A power supply 130 is electrically connected to the plasma arc torch 100such that the first electrode 112 serves as the cathode and the hollowelectrode nozzle 106 serves as the anode. The voltage, power and type ofthe power supply 130 is dependant upon the size, configuration andfunction of the plasma arc torch 100. A gas (e.g., air), fluid (e.g.,water) or steam 110 is introduced into the tangential inlet 120 to forma vortex 132 within the cylindrical vessel 104 and exit through thetangential outlet 102 as discharge 134. The vortex 132 confines theplasma 108 within in the vessel 104 by the inertia (inertial confinementas opposed to magnetic confinement) caused by the angular momentum ofthe vortex, whirling, cyclonic or swirling flow of the gas (e.g., air),fluid (e.g., water) or steam 110 around the interior of the cylindricalvessel 104. During startup, the linear actuator 114 moves the firstelectrode 112 into contact with the hollow electrode nozzle 106 and thendraws the first electrode 112 back to create an electrical arc whichforms the plasma 108 that is discharged through the hollow electrodenozzle 106. During operation, the linear actuator 114 can adjust theposition of the first electrode 112 to change the plasma 108 dischargeor account for extended use of the first electrode 112.

Referring now to FIG. 2, a cross-sectional view comparing andcontrasting a solid oxide cell 200 to a liquid electrolyte cell 250 inaccordance with one embodiment of the present invention is shown. Anexperiment was conducted using the Liquid Electrolyte Cell 250. A carboncathode 202 was connected a linear actuator 204 in order to raise andlower the cathode 202 into a carbon anode crucible 206. An ESAB ESP 150DC power supply rated at 150 amps and an open circuit voltage (“OCV”) of370 VDC was used for the test. The power supply was “tricked out” inorder to operate at OCV.

In order to determine the sheath glow discharge length on the cathode202 as well as measure amps and volts the power supply was turned on andthen the linear actuator 204 was used to lower the cathode 202 into anelectrolyte solution of water and baking soda. Although a steady glowdischarge could be obtained the voltage and amps were too erratic torecord. Likewise, the power supply constantly surged and pulsed due toerratic current flow. As soon as the cathode 202 was lowered too deep,the glow discharge ceased and the cell went into an electrolysis mode.In addition, since boiling would occur quite rapidly and the electrolytewould foam up and go over the sides of the carbon crucible 206, foundrysand was added reduce the foam in the crucible 206.

The 8″ diameter anode crucible 206 was filled with sand and theelectrolyte was added to the crucible. Power was turned on and thecathode 202 was lowered into the sand and electrolyte. Unexpectedly, aglow discharge was formed immediately, but this time it appeared tospread out laterally from the cathode 202. A large amount of steam wasproduced such that it could not be seen how far the glow discharge hadextended through the sand.

Next, the sand was replaced with commonly available clear floralmarbles. When the cathode 202 was lowered into the marbles and bakingsoda/water solution, the electrolyte began to slowly boil. As soon asthe electrolyte began to boil a glow discharge spider web could be seenthroughout the marbles as shown the Solid Oxide Cell 200. Although thiswas completely unexpected at a much lower voltage than what has beendisclosed and published, what was completely unexpected is that the DCpower supply did not surge, pulse or operate erratically in any way. Agraph showing an operating curve for a glow discharge cell in accordancewith the present invention is shown in FIG. 3 based on various tests.The data is completely different from what is currently published withrespect to glow discharge graphs and curves developed from currentlyknown electro-plasma, plasma electrolysis or glow discharge reactors.Glow discharge cells can evaporate or concentrate liquids whilegenerating steam.

Now referring to FIG. 4, a cross-sectional view of a glow discharge cell400 in accordance with one embodiment of the present invention is shown.The glow discharge cell 400 includes an electrically conductivecylindrical vessel 402 having a first end 404 and a second end 406, andat least one inlet 408 and one outlet 410. A hollow electrode 412 isaligned with a longitudinal axis of the cylindrical vessel 402 andextends at least from the first end 404 to the second end 406 of thecylindrical vessel 402. The hollow electrode 412 also has an inlet 414and an outlet 416. A first insulator 418 seals the first end 404 of thecylindrical vessel 402 around the hollow electrode 412 and maintains asubstantially equidistant gap 420 between the cylindrical vessel 402 andthe hollow electrode 412. A second insulator 422 seals the second end406 of the cylindrical vessel 402 around the hollow electrode 412 andmaintains the substantially equidistant gap 420 between the cylindricalvessel 402 and the hollow electrode 412. A non-conductive granularmaterial 424 is disposed within the gap 420, wherein the non-conductivegranular material 424 (a) allows an electrically conductive fluid toflow between the cylindrical vessel 402 and the hollow electrode 412,and (b) prevents electrical arcing between the cylindrical vessel 402and the hollow electrode 412 during a electric glow discharge. Theelectric glow discharge is created whenever: (a) the glow discharge cell400 is connected to an electrical power source such that the cylindricalvessel 402 is an anode and the hollow electrode 412 is a cathode, and(b) the electrically conductive fluid is introduced into the gap 420.

The vessel 402 can be made of stainless steel and the hollow electrodecan be made of carbon. The non-conductive granular material 424 can bemarbles, ceramic beads, molecular sieve media, sand, limestone,activated carbon, zeolite, zirconium, alumina, rock salt, nut shell orwood chips. The electrical power supply can operate in a range from 50to 500 volts DC, or a range of 200 to 400 volts DC. The cathode 412 canreach a temperature of at least 500° C., at least 1000° C., or at least2000° C. during the electric glow discharge. The electrically conductivefluid comprises water, produced water, wastewater, tailings pond water,or other suitable fluid. The electrically conductive fluid can becreated by adding an electrolyte, such as baking soda, Nahcolite, lime,sodium chloride, ammonium sulfate, sodium sulfate or carbonic acid, to afluid.

Referring now to FIG. 5, a cross-sectional view of a glow discharge cell500 in accordance with another embodiment of the present invention isshown. The glow discharge cell 500 includes an electrically conductivecylindrical vessel 402 having a first end 404 and a closed second end502, an inlet proximate 408 to the first end 404, and an outlet 410centered in the closed second end 502. A hollow electrode 504 is alignedwith a longitudinal axis of the cylindrical vessel and extends at leastfrom the first end 404 into the cylindrical vessel 402. The hollowelectrode 504 has an inlet 414 and an outlet 416. A first insulator 418seals the first end 404 of the cylindrical vessel 402 around the hollowelectrode 504 and maintains a substantially equidistant gap 420 betweenthe cylindrical vessel 402 and the hollow electrode 504. Anon-conductive granular material 424 is disposed within the gap 420,wherein the non-conductive granular material 424 (a) allows anelectrically conductive fluid to flow between the cylindrical vessel 402and the hollow electrode 504, and (b) prevents electrical arcing betweenthe cylindrical vessel 402 and the hollow electrode 504 during aelectric glow discharge. The electric glow discharge is createdwhenever: (a) the glow discharge cell 500 is connected to an electricalpower source such that the cylindrical vessel 402 is an anode and thehollow electrode 504 is a cathode, and (b) the electrically conductivefluid is introduced into the gap 420.

The following examples will demonstrate the capabilities, usefulness andcompletely unobvious and unexpected results.

EXAMPLE 1 Black Liquor

Now referring to FIG. 6, a cross-sectional view of a Solid Oxide PlasmaArc Torch System 600 in accordance with another embodiment of thepresent invention is shown. A plasma arc torch 100 is connected to thecell 500 via an eductor 602. Once again the cell 500 was filled with abaking soda and water solution. A pump was connected to the first volute31 of the plasma arc torch 100 via a 3-way valve 604 and the eductor602. The eductor 602 pulled a vacuum on the cell 500. The plasma exitingfrom the plasma arc torch 100 dramatically increased in size. Hence, anon-condensable gas B was produced within the cell 500. The color of thearc within the plasma arc torch 100 when viewed through the sightglass33 changed colors due to the gases produced from the HiTemper™ cell 500.Next, the 3-way valve 604 was adjusted to allow air and water F to flowinto the first volute 31 of plasma arc torch 100. The additional massflow increased the plasma G exiting from the plasma arc torch 100.Several pieces of stainless steel round bar were placed at the tip ofthe plasma G and melted to demonstrate the systems capabilities.Likewise, wood was carbonized by placing it within the plasma stream G.Thereafter the plasma G exiting from the plasma torch 100 was directedinto cyclone separator 610. The water and gases I exiting from theplasma arc torch 100 via second volute 34 flowed into a hydrocyclone 608via a valve 606. This allowed for rapid mixing and scrubbing of gaseswith the water in order to reduce the discharge of any hazardouscontaminants.

A sample of black liquor with 16% solids obtained from a pulp and papermill was charged to the glow discharge cell 500 in a sufficient volumeto cover the floral marbles 424. In contrast to other glow discharge orelectro plasma systems the solid oxide glow discharge cell does notrequire preheating of the electrolyte. The ESAB ESP 150 power supply wasturned on and the volts and amps were recorded by hand. Referringbriefly to FIG. 3, as soon as the power was turned on to the cell 500,the amp meter pegged out at 150. Hence, the name of the ESAB powersupply—ESP 150. It is rated at 150 amps. The voltage was steady between90 and 100 VDC. As soon as boiling occurred the voltage steadily climbedto OCV (370 VDC) while the amps dropped to 75.

The glow discharge cell 500 was operated until the amps fell almost tozero. Even at very low amps of less than 10 the voltage appeared to belocked on at 370 VDC. The cell 500 was allowed to cool and then openedto examine the marbles 424. It was surprising that there was no visibleliquid left in the cell 500 but all of the marbles 424 were coated orcoked with a black residue. The marbles 424 with the black residue wereshipped off for analysis. The residue was in the bottom of the containerand had come off of the marbles 424 during shipping. The analysis islisted in the table below, which demonstrates a novel method forconcentrating black liquor and coking organics. With a starting solidsconcentration of 16%, the solids were concentrated to 94.26% with onlyone evaporation step. Note that the sulfur (“S”) stayed in the residueand did not exit the cell 500.

TABLE Black Liquor Results Total Solids % 94.26 Ash %/ODS 83.64 ICPmetal scan: results are reported on ODS basis Metal Scan Unit F80015Aluminum, Al mg/kg 3590*  Arsenic, As mg/kg <50  Barium, Ba mg/kg 2240* Boron, B mg/kg 60 Cadmium, Cd mg/kg  2 Calcium, Ca mg/kg 29100* Chromium, Cr mg/kg 31 Cobalt, Co mg/kg <5 Copper, Cu mg/kg 19 Iron, Femg/kg 686* Lead, Pb mg/kg <20  Lithium, Li mg/kg 10 Magnesium, Mg mg/kg1710*  Manganese, Mn mg/kg   46.2 Molybdenum, Mo mg/kg 40 Nickel, Nimg/kg <100  Phosphorus, P mg/kg 35 Potassium, K mg/kg 7890  Silicon, Simg/kg 157000*   Sodium, Na mg/kg 102000   Strontium, Sr mg/kg <20 Sulfur, S mg/kg 27200*  Titanium, Ti mg/kg  4 Vanadium, V mg/kg   1.7Zinc, Zn mg/kg 20This method can be used for concentrating black liquor from pulp, paperand fiber mills for subsequent recaustizing.

As can be seen in FIG. 3, if all of the liquid evaporates from the cell500 and it is operated only with a solid electrolyte, electrical arcover from the cathode to anode may occur. This has been tested in whichcase a hole was blown through the stainless steel vessel 402. Electricalarc over can easily be prevented by (1) monitoring the liquid level inthe cell and do not allow it to run dry, and (2) monitoring the amps(Low amps=Low liquid level). If electrical arc over is desirable or thecell must be designed to take an arc over, then the vessel 402 should beconstructed of carbon.

EXAMPLE 2 Arcwhirl® Plasma Torch Attached to Solid Oxide Cell

Referring now to FIG. 7, a cross-sectional view of a Solid Oxide PlasmaArc Torch System 700 in accordance with another embodiment of thepresent invention is shown. A plasma arc torch 100 is connected to thecell 500 via an eductor 602. Once again the cell 500 was filled with abaking soda and water solution. Pump 23 recirculates the baking soda andwater solution from the outlet 416 of the hollow electrode 504 to theinlet 408 of the cell 500. A pump 22 was connected to the first volute31 of the plasma arc torch 100 via a 3-way valve 604 and the eductor602. An air compressor 21 was used to introduce air into the 3-way valve604 along with water F from the pump 22. The pump 22 was turned on andwater F flowed into the first volute 31 of the plasma arc torch 100 andthrough a full view site glass 33 and exited the torch 30 via a secondvolute 34. The plasma arc torch 100 was started by pushing a carboncathode rod (−NEG) 32 to touch and dead short to a positive carbon anode(+POS) 35. A very small plasma G exited out of the anode 35. Next, theHigh Temperature Plasma Electrolysis Reactor (Cell) 500 was started inorder to produce a plasma gas B. Once again at the onset of boilingvoltage climbed to OCV (370 VDC) and a gas began flowing to the plasmaarc torch 100. The eductor 602 pulled a vacuum on the cell 500. Theplasma G exiting from the plasma arc torch 100 dramatically increased insize. Hence, a non-condensable gas B was produced within the cell 500.The color of the arc within the plasma arc torch 100 when viewed throughthe sightglass 33 changed colors due to the gases produced from theHiTemper™ cell 500. Next, the 3-way valve 604 was adjusted to allow airfrom compressor 21 and water from pump 22 to flow into the plasma arctorch 100. The additional mass flow increased the plasma G exiting fromthe plasma arc torch 100. Several pieces of stainless steel round barwere placed at the tip of the plasma G and melted to demonstrate thesystems capabilities. Likewise, wood was carbonized by placing it withinthe plasma stream G. The water and gases exiting from the plasma arctorch 100 via volute 34 flowed into a hydrocyclone 608. This allowed forrapid mixing and scrubbing of gases with the water in order to reducethe discharge of any hazardous contaminants.

Next, the system was shut down and a second cyclone separator 610 wasattached to the plasma arc torch 100 as shown in FIG. 5. Once again theSolid Oxide Plasma Arc Torch System was turned on and a plasma G couldbe seen circulating within the cyclone separator 610. Within the eye orvortex of the whirling plasma G was a central core devoid of any visibleplasma.

The cyclone separator 610 was removed to conduct another test. Todetermine the capabilities of the Solid Oxide Plasma Arc Torch System asshown in FIG. 6, the pump 22 was turned off and the system was operatedonly on air provided by compressor 21 and gases B produced from thesolid oxide cell 500. Next, 3-way valve 606 was slowly closed in orderto force all of the gases through the arc to form a large plasma Gexiting from the hollow carbon anode 35.

Next, the 3-way valve 604 was slowly closed to shut the flow of air tothe plasma arc torch 100. What happened was completely unexpected. Theintensity of the light from the sightglass 33 increased dramatically anda brilliant plasma was discharged from the plasma arc torch 100. Whenviewed with a welding shield the arc was blown out of the plasma arctorch 100 and wrapped back around to the anode 35. Thus, the Solid OxidePlasma Arc Torch System will produce a gas and a plasma suitable forwelding, melting, cutting, spraying and chemical reactions such aspyrolysis, gasification and water gas shift reaction.

EXAMPLE 3 Phosphogypsum Pond Water

The phosphate industry has truly left a legacy in Florida, Louisiana andTexas that will take years to cleanup—gypsum stacks and pond water. Ontop of every stack is a pond. Pond water is recirculated from the pondback down to the plant and slurried with gypsum to go up the stack andallow the gypsum to settle out in the pond. This cycle continues and thegypsum stack increases in height. The gypsum is produced as a byproductfrom the ore extraction process.

There are two major environmental issues with every gyp stack. First,the pond water has a very low pH. It cannot be discharged withoutneutralization. Second, the phosphogypsum contains a slight amount ofradon. Thus, it cannot be used or recycled to other industries. Theexcess water in combination with ammonia contamination produced duringthe production of P₂O₅ fertilizers such as diammonium phosphate (“DAP”)and monoammonium phosphate (“MAP”) must be treated prior to discharge.The excess pond water contains about 2% phosphate a valuable commodity.

A sample of pond water was obtained from a Houston phosphate fertilizercompany. The pond water was charged to the solid oxide cell 500. TheSolid Oxide Plasma Arc Torch System was configured as shown in FIG. 6.The 3-way valve 606 was adjusted to flow only air into the plasma arctorch 100 while pulling a vacuum on cell 500 via eductor 602. The hollowanode 35 was blocked in order to maximize the flow of gases I tohydrocyclone 608 that had a closed bottom with a small collectionvessel. The hydrocyclone 608 was immersed in a tank in order to cool andrecover condensable gases.

The results are disclosed in FIG. 10—Tailings Pond Water Results. Thegoal of the test was to demonstrate that the Solid Oxide Glow DischargeCell could concentrate up the tailings pond water. Turning now to cyclesof concentration, the percent P₂O₅ was concentrated up by a factor of 4for a final concentration of 8.72% in the bottom of the HiTemper™ cell500. The beginning sample as shown in the picture is a colorless,slightly cloudy liquid. The bottoms or concentrate recovered from theHiTemper cell 500 was a dark green liquid with sediment. The sedimentwas filtered and are reported as SOLIDS (Retained on Whatmann #40 filterpaper). The percent SO₄ recovered as a solid increased from 3.35% to13.6% for a cycles of concentration of 4. However, the percent Narecovered as a solid increased from 0.44% to 13.67% for a cycles ofconcentration of 31.

The solid oxide or solid electrolyte 424 used in the cell 500 werefloral marbles (Sodium Oxide). Floral marbles are made of sodium glass.Not being bound by theory it is believed that the marbles were partiallydissolved by the phosphoric acid in combination with the hightemperature glow discharge. Chromate and Molydemun cycled up andremained in solution due to forming a sacrificial anode from thestainless steel vessel 402. Note: Due to the short height of the cellcarryover occurred due to pulling a vacuum on the cell 500 with eductor602. In the first run (row 1 HiTemper) of FIG. 10 very little fluorinewent overhead. That had been a concern from the beginning that fluorinewould go over head. Likewise about 38% of the ammonia went overhead. Itwas believed that all of the ammonia would flash and go overhead.

A method has been disclosed for concentrating P₂O₅ from tailings pondfor subsequent recovery as a valuable commodity acid and fertilizer.

Now, returning back to the black liquor sample, not being bound bytheory it is believed that the black liquor can be recaustisized bysimply using CaO or limestone as the solid oxide electrolyte 424 withinthe cell 500. Those who are skilled in the art of producing pulp andpaper will truly understand the benefits and cost savings of not havingto run a lime kiln. However, if the concentrated black liquor must begasified or thermally oxidized to remove all carbon species, the marbles424 can be treated with the plasma arc torch 100. Referring back to FIG.6, the marbles 424 coated with the concentrated black liquor or theconcentrated black liquor only is injected between the plasma arc torch100 and the cyclone separator 610. This will convert the black liquorinto a green liquor or maybe a white liquor. The marbles 424 may beflowed into the plasma arc torch nozzle 31 and quenched in the whirlinglime water and discharged via volute 34 into hydrocyclone 608 forseparation and recovery of both white liquor and the marbles 424. Thelime will react with the NaO to form caustic and an insoluble calciumcarbonate precipitate.

EXAMPLE 4 Evaporation, Vapor Compression and Steam Generation for EORand Industrial Steam Users

Turning to FIG. 4, several oilfield wastewaters were evaporated in thecell 400. In order to enhance evaporation the suction side of a vaporcompressor (not shown) can be connected to upper outlet 410. Thedischarge of the vapor compressor would be connected to 416. Not beingbound by theory, it is believed that alloys such as Kanthal®manufactured by the Kanthal® corporation may survive the intense effectsof the cell as a tubular cathode 412, thus allowing for a novel steamgenerator with a superheater by flowing the discharge of the vaporcompressor through the tubular cathode 412. Such an apparatus, methodand process would be widely used throughout the upstream oil and gasindustry in order to treat oilfield produced water and frac flowback.

Several different stainless steel tubulars were tested within the cell500 as the cathode 12. In comparison to the sheath glow discharge thetubulars did not melt. In fact, when the tubulars were pulled out, amarking was noticed at every point a marble was in contact with thetube.

This gives rise to a completely new method for using glow discharge totreat metals.

EXAMPLE 5 Treating Tubes, Bars, Rods, Pipe or Wire

There are many different companies applying glow discharge to treatmetal. However, many have companies have failed miserably due to arcingover and melting the material to be coated, treated or descaled. Theproblem with not being able to control voltage leads to spikes. Bysimply adding sand or any solid oxide to the cell and feeding the tubecathode 12 through the cell 500 as configured in FIG. 2, the tube, rod,pipe, bars or wire can be treated at a very high feedrate.

EXAMPLE 6 Solid Oxide Plasma Arc Torch

There truly exists a need for a very simple plasma torch that can beoperated with dirty or highly polluted water such as sewage flusheddirectly from a toilet which may contain toilet paper, feminine napkins,fecal matter, pathogens, urine and pharmaceuticals. A plasma torchsystem that could operate on the aforementioned waters could potentiallydramatically affect the wastewater infrastructure and future costs ofmaintaining collection systems, lift stations and wastewater treatmentfacilities.

By converting the contaminated wastewater to a gas and using the gas asa plasma gas could also alleviate several other growingconcerns—municipal solid waste going to landfills, grass clippings andtree trimmings, medical waste, chemical waste, refinery tank bottoms,oilfield wastes such as drill cuttings and typical everyday householdgarbage. A simple torch system which could handle both solid waste andliquids or that could heat a process fluid while gasifying biomass orcoal or that could use a wastewater to produce a plasma cutting gaswould change many industries overnight.

One industry in particular is the metals industry. The metals industryrequires a tremendous amount of energy and exotic gases for heating,melting, welding, cutting and machining.

Turning now to FIGS. 8 and 9, a truly novel plasma torch 800 will bedisclosed in accordance with the preferred embodiments of the presentinvention. First, the Solid Oxide Plasma Torch is constructed bycoupling the plasma arc torch 100 to the cell 500. The plasma arc torchvolute 31 and electrode 32 are detached from the eductor 602 andsightglass 33. The plasma arc torch volute 31 and electrode assembly 32are attached to the cell 500 vessel 402. The sightglass 33 is replacedwith a concentric type reducer 33. It is understood that the electrode32 is electrically isolated from the volute 31 and vessel 402. Theelectrode 32 is connected to a linear actuator (not shown) in order tostrike the arc.

Continuous Operation of the Solid Oxide Transferred Arc Plasma Torch 800as shown in FIG. 8 will now be disclosed for cutting or melting anelectrically conductive workpiece. A fluid is flowed into the suctionside of the pump and into the cell 500. The pump is stopped. A firstpower supply PS1 is turned on thus energizing the cell 500. As soon asthe cell 500 goes into glow discharge and a gas is produced valve 16opens allowing the gas to enter into the volute 31. The volute 31imparts a whirl flow to the gas. A switch 60 is positioned such that asecond power supply PS2 is connected to the workpiece and the −negativeside of PS2 is connected to the −negative of PS1 which is connected tothe centered cathode 504 of the cell 500. The entire torch is lowered sothat an electrically conductive nozzle 13-C touches and is grounded tothe workpiece. PS2 is now energized and the torch is raised from theworkpiece. An arc is formed between cathode 504 and the workpiece.

Centering the Arc—If the arc must be centered for cutting purposes, thenPS2's −negative lead would be attached to the lead of switch 60 thatgoes to the electrode 32. Although a series of switches are not shownfor this operation, it will be understood that in lieu of manuallyswitching the negative lead from PS2 an electrical switch similar to 60could be used for automation purposes. The +positive lead would simplygo to the workpiece as shown. A smaller electrode 32 would be used suchthat it could slide into and through the hollow cathode 504 in order totouch the workpiece and strike an arc. The electrically conductivenozzle 802 would be replaced with a non-conducting shield nozzle. Thissetup allows for precision cutting using just wastewater and no othergases.

Turning to FIG. 9, the Solid Oxide Non-Transferred Arc Plasma Torch 800is used primarily for melting, gasifying and heating materials whileusing a contaminated fluid as the plasma gas. Switch 60 is adjusted suchthat PS2 +lead feeds electrode 32. Once again electrode 32 is nowoperated as the anode. It must be electrically isolated from vessel 402.When gas begins to flow by opening valve 16 the volute 31 imparts a spinor whirl flow to the gas. The anode 32 is lowered to touch the centeredcathode 504. An arc is formed between the cathode 32 and anode 504. Theanode may be hollow and a wire may be fed through the anode 504 forplasma spraying, welding or initiating the arc.

The entire torch is regeneratively cooled with its own gases thusenhancing efficiency. Likewise, a waste fluid is used as the plasma gaswhich reduces disposal and treatment costs. Finally, the plasma may beused for gasifying coal, biomass or producing copious amounts of syngasby steam reforming natural gas with the hydrogen and steam plasma.

Both FIGS. 8 and 9 have clearly demonstrated a novel Solid Oxide PlasmaArc Torch that couples the efficiencies of high temperature electrolysiswith the capabilities of both transferred and non-transferred arc plasmatorches.

EXAMPLE 7 Multi-Mode Plasma Arc Torch

Now referring to FIG. 11, a multi-mode plasma arc torch 1100 inaccordance with one embodiment of the present invention is shown. Themulti-mode plasma arc torch 1100 is a plasma arc torch 100 of FIG. 1that is modified to include some of the attributes of the glow dischargecell 500 of FIG. 5. The multi-mode plasma arc torch 1100 includes acylindrical vessel 104 having a first end 116 and a second end 118. Atangential inlet 120 is connected to or proximate to the second end 118and a tangential outlet 102 is connected to or proximate to the firstend 116. An electrode housing 122 is connected to the first end 116 ofthe cylindrical vessel 104 such that a first electrode 112 is alignedwith the longitudinal axis 124 of the cylindrical vessel 104, extendsinto the cylindrical vessel 104, and can be moved along the longitudinalaxis 124. Moreover, a linear actuator 114 is connected to the firstelectrode 112 to adjust the position of the first electrode 112 withinthe cylindrical vessel 104 along the longitudinal axis of thecylindrical vessel 124 as indicated by arrows 126. The hollow electrodenozzle 106 is connected to the second end 118 of the cylindrical vessel104 such that the centerline of the hollow electrode nozzle 106 isaligned with the longitudinal axis 124 of the cylindrical vessel 104. Inthe embodiment shown, the tangential inlet 120 is volute attached to thesecond end 118 of the cylindrical vessel 104, the tangential outlet 102is a volute attached to the first end 116 of the cylindrical vessel 104,the electrode housing 122 is connected to the outlet volute 102, and thehollow electrode nozzle 106 (cylindrical configuration) is connected tothe inlet volute 120. Note that the multi-mode plasma arc torch 1100 isnot shown to scale.

A substantially equidistant gap 420 is maintained between thecylindrical vessel 402 and the hollow electrode nozzle 106. In someembodiments, a non-conductive granular material 424 is disposed withinthe gap 420, wherein the non-conductive granular material 424 allows anelectrically conductive fluid to flow between the cylindrical vessel 402and the hollow electrode nozzle 106. In other embodiments, thenon-conductive granular material 424 is not used. Note that using thenon-conductive granular material 424 improves the efficiency of thedevice by increasing the contact surface area for the fluid, but is notrequired. If the cylindrical vessel 402 is metallic, the non-conductivegranular material 424 can prevent electrical arcing between thecylindrical vessel 402 and the hollow electrode nozzle 106 during aelectric glow discharge. The shape of the hollow portion 128 of thehollow electrode nozzle 106 can be varied as needed to provide thedesired operational results as shown in FIGS. 12 and 13A-F. Other shapescan be used.

A power supply 130 is electrically connected to the multi-mode plasmaarc torch 1100 such that the first electrode 112 serves as the cathodeand the hollow electrode nozzle 106 serves as the anode. The voltage,power and type of the power supply 130 are dependent upon the size,configuration and function of the multi-mode plasma arc torch 1100. Insome embodiments, a second electrode 1102 can be added as an (+) anode,such as a graphite electrode, along the longitudinal axis 124 to deadshort to the first electrode 112 (−) cathode. This configuration allowsfor continuous feed of electrodes for continuous duty operation. Likethe first electrode 112, the second electrode 1102 can be moved ineither direction along the longitudinal axis 124 as shown by arrow 126.

A fluid, slurry, liquid/gas mixture or other pumpable material 1104 isintroduced into the tangential inlet 120 to a desired fluid level 1106,which can vary based on the desired operational results, within thecylindrical vessel 104. Note that the actual level will typicallyfluctuate during operation. During startup, the linear actuator 114moves the first electrode 112 into contact with the hollow electrodenozzle 106 or the second electrode 1102 and then either leaves the firstelectrode 112 there (dead short resistive heating mode) or draws thefirst electrode 112 back a specified distance yet remains below thedesired fluid level 1106. As shown in FIG. 12, the linear actuator 114can adjust the position of the first electrode 112 to operate themulti-mode plasma arc torch 1100 in a dead short resistive mode 1200, asubmerged arc mode 1202, an electrolysis mode 1204 or a glow dischargemode 1206. As the fluid 1104 is heated in accordance with one of thesefour operating modes, gases or steam 1108 will rise and exit throughtangential outlet 102. The fluid 1104 can be recirculated by allowingthe fluid 1004 to flow through the hollow electrode nozzle 106 andreenter the cylindrical vessel 104 via tangential inlet 120. Note thatthe fifth operating mode is the plasma arc mode as described and shownin FIG. 1.

Referring now to FIGS. 13A-13F, various examples of shapes for thehollow electrode nozzle 106 are shown. FIG. 13A shows a straight hollowelectrode nozzle 106 a. FIG. 13B shows a straight hollow electrodenozzle flange 106 b. FIG. 13C shows a tapered hollow electrode nozzle106 c. FIG. 13D shows a tapered hollow electrode nozzle flange 106 d.FIG. 13E shows a hollow electrode nozzle counterbore flange 106 e. FIG.13F shows a hollow electrode nozzle counterbore exterior tapered flange106 f. Note that FIG. 12 shows a hollow electrode nozzle counterbore106. Other shapes can be used as will be appreciated by those skilled inthe art.

Now referring to FIG. 14, a diagram of a dual first electrode 1400 inaccordance with another embodiment of the present invention is shown.The dual first electrode is a combination of the first electrode 112 anda larger diameter, but shorter, third electrode 1402 that is eitherelectrically connected to the first electrode 112 or the power supply130 (same polarity as the first electrode 112). The third electrode 1402can be moved up and down as indicated by arrows 126. Moreover, the thirdelectrode 1402 can be physically connected to the first electrode 112.The third electrode 1402 provides additional electrode surface area toenhance the process.

Referring now to FIG. 15, a diagram of a system 1500 to operate theplasma arc torch 100 or 1100 in five operating modes in accordance withthe present invention is show. The system 1500 includes a plasma arctorch 100 or 1100, three three-way valves 1502 a, 1502 b, 1502 c and apump and/or compressor 1504. The first three-way valve 1502 a isconnected to the inlet/outlet (depends on the operating mode) located atthe first end 116 of the plasma arc torch 100 or 1100, and has a firstvalve inlet/outlet (depends on the operating mode) 1508 a. The secondthree-way valve 1502 b is connected to the inlet/outlet (depends on theoperating mode) located at the second end 118 of the plasma arc torch100 or 1100, and has a second valve inlet/outlet (depends on theoperating mode) 1508 b. The third three-way valve 1502 c is connected tothe exterior end of the hollow electrode nozzle 106, and has a thirdvalve inlet/outlet (depends on the operating mode) 1508 c. Each of thethree-way valves 1502 a, 1502 b, 1502 c are connected to the discharge1506 of the pump and/or compressor 1504. The fluid, slurry, liquid/gasmixture or other pumpable/compressable material 1104 enters the suction1510 of the pump and/or compressor 1504. The three-way valves 1502 areadjusted to operate the plasma arc torch 100 or 1100 in the five modes,while adjusting the first electrode 112 with the linear actuator 114.

Operating Mode 1: Plasma Arc

-   -   a. Compressed and/or pressurized fluid 1104 from a        pump/compressor 1504 is flowed into three-way valve 1502 a and        then into plasma arc torch 100 or 1100.    -   b. Three-way valve 1502 b is fully open to allow fluid to flow        out of plasma arc torch 100 or 1100 and to outlet 1508 b.    -   c. Three-way valve 1502 c is fully open to flow to outlet 1508        c.    -   d. Ensure (−) first electrode 112 is dead shorted to (+) hollow        electrode nozzle 106.    -   e. Ensure whirl glow is established.    -   f. Turn power supply 130 ON.    -   g. Using linear Actuator 114 pull back the (−) first electrode        112 to establish and arc.    -   h. Arc is transferred from (−) to (+).    -   i. Whirling gas flowing through (+) hollow electrode nozzle 106        forms a plasma.    -   j. Very small plasma may be discharged through outlet 1508 c.    -   k. Three-way valve 1502 b may be throttled to increase/decrease        plasma flow through (+) hollow electrode nozzle 106 and outlet        1508 c.    -   l. Three-way valve 1502 b may be shut to flow all fluid into (+)        hollow electrode nozzle 106 and outlet 1508 c.

Operating Mode 2: Resistive Heating

-   -   a. Compressed and/or pressurized fluid 1104 from a        pump/compressor 1504 is flowed into three-way valve 1502 b and        then into plasma arc torch 100 or 1100    -   b. Three-way valve 1502 a is fully open to flow out of plasma        arc torch 100 or 1100 and to outlet 1508 a.    -   c. Three-way valve 1502 b is throttled to allow fluid to flow        into plasma arc torch 100 or 1100 very slowly.    -   d. Three-way valve 1502 c is shut.    -   e. The (−) first electrode 112 is dead shorted to (+) hollow        electrode Nozzle 106.    -   f. Power supply 130 is turned ON.    -   g. Resistive mode begins.    -   h. Vapors exit through three-way valve 1502 a and outlet 1508 a

Operating Mode 3: Submerged Arc

-   -   a. Valves remain aligned as in Operating Mode 2 above.    -   b. Power supply 130 is still ON.    -   c. The (−) first electrode 112 is slowly within drawn from (+)        hollow electrode nozzle 106.    -   d. The system shifts from resistive heating to submerged arc        mode.    -   e. Three-way valve 1502 c may be opened to allow pressurized        fluid from pump/compressor 1504 to flow through (+) hollow        electrode nozzle 106 and into plasma arc torch 100 or 1100.    -   f. Vapors exit the plasma arc torch 100 or 1100 through outlet        1508 a.

Operating Mode 4: Electrolysis

-   -   a. Valves remain aligned as in Operating Mode 2 above.    -   b. Power supply 130 is still ON.    -   c. The (−) first electrode 112 is slowly within drawn further        from (+) hollow electrode nozzle 106 using linear actuator 114.    -   d. The system shifts from submerged arc to electrolysis mode.

Operating Mode 5: Glow Discharge

-   -   a. Valves remain aligned as in Operating Mode 2 above.    -   b. Power supply 130 is still ON.    -   c. The (−) first electrode 112 is slowly within drawn further        from (+) hollow electrode nozzle 106 using linear actuator 114.    -   d. Monitor the power supply 130 voltage.    -   e. When the voltage increases to open circuit voltage (“OCV”),        the system is operating in glow discharge mode.    -   f. The amps will decrease.    -   g. Three-way valve 1502 b and three-way valve 1502 c may be        adjusted to allow pressurized flow to enter plasma arc torch 100        or 1100 either through three-way valve 1502 b or three-way valve        1502 c, and/or three-way valve 1502 b and three-way valve 1502 c        aligned for fluid flow recirculation using pump/compressor 1504.    -   h. Vapors exit from plasma arc torch 100 or 1100 and out of        outlet 1508 a.

The plasma arc torch 100 or 1100 can be adapted for use in manyapplications by attaching various devices to the exterior of the hollowelectrode nozzle 106 or the three-way valve 1502 c. The device mayinclude, but are not limited to, valve, vessel, flange, cover, hatch,tee, electrode stinger, eductor, injector, pump, compressor, screwpress, auger, ram feeder, mixer, extruder, T-fired boiler, coker drum,gasifier, pipe, conduit, tubing, submerged melting furnace, rotary kiln,rocket nozzle, thermal oxidizer, cyclone separator inlet, cycloneseparator vortex collector, cyclone separator overflow or underflow,cyclone combustor, precombustion chamber, ice screw-in cylinder, turbinecombustor, pulse detonation engine, combustion exhaust pipe/stack,thermal oxidizer, flare, water tank, raw sewage pipe, wastewaterinfluent/effluent piping/conduit, anaerobic digester influent/effluentpiping, sludge press/centrifuge inlet/outlet piping, potable waterpiping point of use or point of entry, water storage tank, CNCcutting/welding table, direct contact water heater, wet gas chlorineline/pipe, O&G wellhead, O&G produced water piping, ship ballast waterline, engine fuel line, froth flotation inlet/outlet, conduit extendinginside tank/vessel, submerged inside tank/vessel, porous tube, wedgewire screen, well screen, filter, activated carbon filter, ceramicfilter, cat cracker catalyst recycle line, hospital vacuum suction pump,cooling tower piping, steam separator, superheater, boiler waterfeedwater piping, ro reject piping, vacuum chamber inlet/outlet,graywater discharge piping, ship ballast water inlet/outlet piping,bilge water inlet/outlet piping, toilet discharge piping,grinder/shredder/macerator discharge piping, and/or kitchen sink garbagedisposer outlet piping, nuclear reactor containment building forhydrogen mitigation (hydrogen igniter), infrared heating element/piping,charge heater, furnace and/or coke calciner.

Steam Plasma Arc Mode

Three-way valves 1502 a and 11502 b were connected to the tangentialinlet 118 and tangential outlet 134 of the plasma arc torch 100disclosed in FIG. 1. During testing with the three-way valve 1502 battached as shown, when the valve V# is fully closed, the plasma 108 ofFIG. 1 was discharged from the plasma arc torch 100 and was measuredwith an optical pyrometer. With the gases produced from the CELL 500 asshown in FIGS. 6 and 7, the plasma 108 temperature was measured at+3,000° C. (+5,400° F.). With only air, the plasma 108 was measured at+2,100° C. (+3,800° F.). The system as shown in 700 was operated with aceramic TEE as disclosed in FIG. 17 and shown attached to the plasma arctorch 100 in FIG. 14.

Likewise, a Filter Screen was attached as shown in FIG. 18 to the plasmaarc torch 100. Wood pellets produced with a pelletizer were placed inthe Filter Screen prior to attaching to the plasma arc torch 100. Thesteam plasma fully carbonized the wood pellets.

The plasma arc torch 100 Filter Screen is particularly useful for remoteand/or stand alone water treatment and black water (raw sewage)applications.

Resistive Heating/Dead Short

The plasma arc torch 100 or 1100 is started by dead-shorting the cathodeto the anode with power supply in the off position. Next, the vessel ispartially filled by jogging the pump. Next the power supply is turned onallowing the system to operate in a resistive heating mode. The benefitto this system is preventing the formation of gases such as chlorine ifsodium chloride is present within the water and/or wastewater. Thefluid, water and/or wastewater is heat treated which is commonlyreferred to as pasteurization.

Submerged Arc Oxidation and Combustion

If the system is to be operated in a Submerged Arc Mode, the cathode issimply withdrawn from the anode. A submerged arc will be formedinstantly. This will produce non-condensible gases such as hydrogen andoxygen by splitting water. In order to aid in forming a gas vortexaround the arc gases such as but not limited to methane, butane,propane, air, oxygen, nitrogen, argon, hydrogen, carbon dioxide, argon,biogas and/or ozone or any combination thereof can be added between thepump and inlet 1502 a or 1502 b with an injector (not shown). However,it is well known that hydrogen peroxide will convert to oxygen and waterwhen irradiated with UV light. Thus, the plasma arc torch 100 or 1100will convert hydrogen peroxide to free radicals and oxygen for operationas an advanced oxidation system.

On the other hand, the present invention's Submerged Arc Mode is ideallysuited for submerged combustion. It is well known that submergedcombustion is very efficient for heating fluids. Likewise, it is wellknown and understood that gases and condensates are produced along withheavy oil from Oil and Gas wells. In addition, the oil sands frothflotation process produces tailings and wastewater with residual solventand bitumen.

The remaining fossil fuels left in produced water and/or froth flotationprocesses can be advantageously used in the present invention. Since theplasma arc torch 100 or 1100 is a cyclone separator then the lighterhydrocarbons will report to the plasma center. Consequently by spargingair into the plasma arc torch 100 or 1100 it can be operated as asubmerged arc combustor.

For example, to ensure that the arc is not extinguished a secondelectrode can be added to the plasma arc torch 100 or 1100 as shown inFIG. 17's TEE Electrode Linear Actuator. Air and/or an air/fuel mixturecan be flowed into the TEE and converted into a Rotating Plasma ArcFlame. The fluid to be heated will enter into one volute while exitingthe other volute in combination with hot combusted gases. On the otherhand, the air/fuel may be added to the fluid entering into the plasmaarc torch 100 or 1100. Three-way valve 1502 b would be shut. Thus, themixture of combusted gases and water would flow through the anode nozzleand exit out of the TEE. A volute or Cyclone Separator may be used inlieu of the TEE. If a Cyclone Separator is used, then the plasma arctorch 100 or 1100 can be operated as a Torch while shooting a plasmainto the vortex of the whirlpool of water within the Cyclone Separator.The benefit of the second (+) electrode is to ensure that the arcremains centered and is not blown out. The discharge from the TEE,Volute or Cyclone Separator would be flowed into a tank (not shown) orstand pipe thus allowing complete mixture and transfer of heat from thenon-condensible gas bubbles to the water/fluid.

Electrolysis

In order to transition to an electrolysis mode the electrode iswithdrawn a predetermined distance from the anode nozzle or anodeelectrode. This distance is easily determined by recording the amps andvolts of the power supply as shown by the GRAPH in FIG. 3. The liquidlevel is held constant by flowing liquid into the plasma arc torch 100or 1100 by jogging the pump or using a variable speed drive pump tomaintain a constant liquid level.

Although not shown a grounding clamp can be secured to the vessel inorder to maintain an equidistant gap between the vessel and cathode,provided the vessel is constructed of an electrically conductedmaterial. However, the equidistant gap can be maintained between theanode nozzle and cathode and electrically isolating the vessel forsafety purposes. Glass and/or ceramic lined vessels and piping arecommon throughout many industries.

By operating in an electrolysis mode this allows for the production ofoxidants in particularly sodium hypochlorite (bleach), if sodiumchloride is present or added to the water. Bleach is commonly used onoffshore production platforms for disinfecting sponsoon water, potablewater and raw sewage. Since electrolysis is occurring between and withinthe equidistance gap between the (+) anode nozzle and (−) cathodeelectrode the present invention overcomes the problems associated withelectrolyzers used on production platforms as well as ships for ballastwater disinfection.

By installing two or more plasma arc torch 100 or 1100, one can beoperated in a submerged arc combustion mode, while the other is operatedin an electrolysis mode. The Submerged ArcWhirl® Combustor would beconfigured as shown in FIG. 18 with a TEE and Electrode and an airejector would siphon the hydrogen generated from the plasma arc torch100 or 1100. Another benefit for using the ArcWhirl® in a Plasma ArcCombustion mode is that the Ultraviolet (“UV”) Light produced from theplasma arc and the electrodes will dechlorinate the water thuseliminating adding a reducing agent to the water.

A simple but effective raw sewage system can be constructed by attachingthe plasma arc torch 100 or 1100 to a common filter vessel in which thefilter screen would be coupled directly to the plasma arc torch 100 or1100. Referring to FIG. 18 the plasma arc torch 100 or 1100 is coupledto the Filter Screen. The ArcWhirl® Filter Screen is then inserted intoa common filter vessel up to the Filter Screen Flange. The plasma arctorch 100 or 1100 is operated in an electrolysis mode allowing the rawsewage to flow through the anode nozzle and into the filter screen.Solids would be trapped in the filter screen.

The filter screen can be cleaned by several methods. First the screencan simply be backwashed. Second the screen can be cleaned by simplyplacing the ArcWhirl® in a Plasma Arc Mode and either steam reformingthe solids or incinerating the solids using an air plasma. However, athird mode can be used which allows for a combination of back washingand glow discharge.

Glow Discharge

To transition to Glow Discharge, the liquid level can be decreased bythrottling three-way valve 1502 b until the plasma arc torch 100 or 1100goes into glow discharge. This is easily determined by watching voltsand amps. When in glow discharge the power supply voltage will be at ornear open circuit voltage. However, to rapidly transition fromElectrolysis to Glow Discharge the cathode electrode is extracted untilthe power supply is at OCV. This can be determined by viewing the glowdischarge thru a sight glass or watching the voltage meter.

This novel feature also allows for FAIL SAFE OPERATION. If the pump isturned off or fluid flow is stopped then all of the water will beblowndown through the anode nozzle of the plasma arc torch 100 or 1100.Electrical flow will stop and thus the system will not produce any gasessuch as hydrogen.

To control the liquid level a variable speed drive pump in combinationwith three-way valve 1502 c may be used to control the liquid level tomaintain and operate in a glow discharge mode. Another failsafe feature,such as a spring, can be added to the linear actuator such that thesystem fails with the cathode fully withdrawn.

The mode of operation can be reversed from Glow Discharge toElectrolysis to Arc and then to Resistive Heating. By simply startingwith the cathode above the water level within the vessel, then slowlylowering the cathode to touch the surface of the liquid, the plasma arctorch 100 or 1100 will immediately go into glow discharge mode.Continually lowering the cathode will shift the system to electrolysisthen to arc then to resistive heating.

Now to operate the plasma arc torch 100 or 1100 as a plasma torch,water/liquid flow may be reversed and blowdown three-way valve 1502 c isfully opened to allow the plasma to discharge from the plasma arc torch100 or 1100. Adding an anode electrode as shown in FIG. 17 will aid inmaintaining an arc. However, if a sufficient amount of gas in entrainedin the water and a gas vortex is formed, the water/liquid can be flowedthrough the plasma arc torch 100 or 1100 in a Plasma Arc Mode.

Although no granular media is needed for this configuration it will beunderstood that granular media may be added to enhance performance.Likewise, what has not been previously disclosed is that thisconfiguration always for purging the vessel and removing the granularmedia by reversing the flow through the system. Referring to FIG. 1outlet 118 is used as the inlet and inlet 120 is used as the outlet.This configuration will work for any fluid whether it is more dense orless dense than water and/or the liquid flowing through the system. Ifthe material density is greater than the liquid the granular materialwill flow through 120. If the material is less dense then the liquidthen it will flow through the nozzle.

FIG. 16 shows a method for securing the (+) hollow electrode nozzle 106to the volute of plasma arc torch 100 or 1100 using flanges 1602 a, 1602b as a coupling means. It will be understood that any type of couplerthat will hold and secure the (+) hollow electrode nozzle 106 willsuffice for use in the present invention. Likewise, using couplers orflanges on both sides of the (+) hollow electrode nozzle 106 allows forit to be flipped and used as a protruding or reducer type couplingnozzle.

In particularly, remote applications that are in dire need of a solutionare potable water treatment and black water (raw sewage) treatment. Forexample, remote water and wastewater applications can be found onoffshore drilling rigs, offshore production platforms, ships, cabins,base camps, military posts/camps, small villages in desert and/or aridenvironments and many developing countries that do not have centralizedwater and wastewater treatment facilities. Another remote application iselectricity produced from wind and solar farms. Likewise, oil and gaswells that are not placed in production such as stranded gas can beconsidered a remote application. Also, after a natural disaster, such asa hurricane or tsunami basic services such as garbage/trash collection,water treatment and wastewater treatment facilities may be destroyed,thus there is a dire need for water disinfection as well as raw sewagetreatment in addition to handling the buildup of trash.

The inventor of the present invention has tested this configuration withan ESAB EPW 360 power supply. The EPW 360 is a “Chopper” type DC powersupply operating at a frequency of 18,000 Hertz. The above describedconfiguration held voltage at an extremely steady state. The discharge134 was throttled with a valve. Whether the valve was open, shut orthrottled the voltage remained rock steady. Likewise, the EPW 360current control potentiometer was turned down to less than 30 amps andthe electrodes were positioned to hold 80 volts. This equates to a powerrating of about 2,400 watts. The EPW 360 is rated at 360 amps with anopen circuit voltage of 360 vdc. At a maximum power rating of 129,600watts DC, then: 129,600÷2,400=54.

Consequently, the plasma arc torch 100 of the present invention clearlydemonstrated a turn down rate of 54 without any additional electroniccontrols, such as a secondary high frequency power supply. That isvirtually unheard of within the plasma torch world. For example,Pyrogensis markets a 25 kw torch operated in the range of 8-25 kW (A 3:1turn down ratio). Furthermore the present invention's plasma arc torch100 does not require any cooling water. The Pyrogensis torch requirescooling with deionized water. Deionized (“DI”) water is used because theDI water is flowed first into one electrode then into the shield oranother part of the torch. Consequently, DI water is used to avoidconducting electricity from the cathode to the anode via the coolingmedia. In addition, heat rejection is another impediment for using anindirectly cooled plasma torch. An indirectly cooled plasma torch mayreject upwards of 30% of the total input power into the cooling fluid.

The plasma arc torch 100 as disclosed in FIGS. 1, 6, 7 is a liquid/gasseparator and extreme steam superheater forming an ionizedsteam/hydrogen plasma when coupled to the glow discharge cell 500 and/orany steam source. As disclosed in FIGS. 6 and 7 the plasma arc torch 100can easily be controlled by manipulating valves 604 and 606

The plasma arc torch 100 as shown in FIG. 1 is similar to a blow-backtorch. For example the (−) negative electrode 112 will dead short andshut flow through the (+) anode nozzle 106 by adjusting the linearactuator 114. However, by adding control valve 604 to the discharge 134,this allows for the plasma arc torch 100 to be operated in a resistiveheating mode.

Referring now to FIG. 17 while comparing to FIGS. 1 and 12A by selectingthe (+) anode nozzle(s) as shown in FIG. 1 and/or 12A, then thecombination of the (−) electrode rod and (+) and anode nozzle form astopper valve V3 as shown in FIG. 23. Thus, this allows for controllingthe flow in/out of the (+) anode nozzle.

The present invention's plasma arc torch 100 has been tested andoperated with various attachments coupled to the (+) anode nozzle. V4represents a partial list of attachments selected from a groupconsisting of a cyclone separator, volute, pump/compressor, filterscreen, ejector/eductor, cross, Screw Feeder, Valve, TEE, Electrode &Linear Actuator, Wave Guide and RF Coil that may be attached alone or inany combination thereof to the (+) Anode Nozzle.

FIG. 18 demonstrates how the Attachments V4 may be connected to theplasma arc torch 100. For example, the plasma arc torch 100 may have anadditional Electrode with a Linear Actuator coupled by means of a TEE.It will be understood that the coupling means may be selected from anytype of coupling device know in the art, ranging from flanges, quickconnectors, welding in addition to using the cyclone separator as shownin FIG. 18 with quick connectors such as sanitary type clamps.

By adding a secondary electrode and linear actuator this allows forcontinuous feeding of electrodes in order to increase the life of theanode nozzle. Furthermore, referring to the anode nozzle of FIG. 12B theadditional electrode allows for operating in an Arc Mode by deadshorting the electrodes together.

The foregoing description of the apparatus and methods of the inventionin preferred and alternative embodiments and variations, and theforegoing examples of processes for which the invention may bebeneficially used, are intended to be illustrative and not for purposeof limitation. The invention is susceptible to still further variationsand alternative embodiments within the full scope of the invention,recited in the following claims.

What is claimed is:
 1. A method for operating a multi-mode plasma arctorch comprising the steps of: providing the multi-mode plasma arc torchcomprising a cylindrical vessel having a first end and a second end, afirst tangential inlet/outlet connected to or proximate to the firstend, a second tangential inlet/outlet connected to or proximate to thesecond end, an electrode housing connected to the first end of thecylindrical vessel such that a first electrode is (a) aligned with alongitudinal axis of the cylindrical vessel, and (b) extends into thecylindrical vessel, and a hollow electrode nozzle connected to thesecond end of the cylindrical vessel such that a center line of thehollow electrode nozzle is aligned with the longitudinal axis of thecylindrical vessel, the hollow electrode having a first end disposedwithin the cylindrical vessel and a second end disposed outside thecylindrical vessel; and operating the multi-mode plasma arc torch in adead short resistive mode, a submerged arc mode, an electrolysis mode, aglow discharge mode or a plasma arc mode by adjusting a position of thefirst electrode with respect to the hollow electrode.
 2. The method asrecited in claim 1, further comprising a non-conductive granularmaterial disposed between the hollow electrode nozzle and thecylindrical vessel.
 3. The method as recited in claim 1, wherein thenon-conductive granular material comprises marbles, ceramic beads,molecular sieve media, sand, limestone, activated carbon, zeolite,zirconium, alumina, rock salt, nut shell or wood chips.
 4. The method asrecited in claim 1, the first end of the cylindrically shaped electrodehaving a first inner diameter that is larger than a second innerdiameter of the second end of the cylindrically shaped electrode nozzle.5. The method as recited in claim 4, the first inner diameter and thesecond inner diameter forming a counterbore.
 6. The method as recited inclaim 4, further comprising a first tapered portion within thecylindrically shaped electrode that transitions from the first innerdiameter to the second inner diameter.
 7. The method as recited in claim4, further comprising a second tapered portion within the cylindricallyshaped electrode that transitions from the first inner diameter to athird inner diameter at the first end of the cylindrically shapedelectrode wherein the third inner diameter is larger than the firstinner diameter.
 8. The method as recited in claim 1, the hollowelectrode nozzle having an external flange.
 9. The method as recited inclaim 1, wherein the step of operating the multi-mode plasma arc torchin the dead short resistive mode comprises adjusting the position of thefirst electrode to contact the hollow electrode nozzle.
 10. The methodas recited in claim 1, wherein the step of operating the multi-modeplasma arc torch in the submerged arc mode comprises adjusting theposition of the first electrode to extend into the hollow electrodenozzle proximate to the second end of the hollow electrode nozzle. 11.The method as recited in claim 1, wherein the step of operating themulti-mode plasma arc torch in the electrolysis mode comprises adjustingthe position of the first electrode to extend into the hollow electrodenozzle proximate to the first end of the hollow electrode nozzle. 12.The method as recited in claim 1, wherein the step of operating themulti-mode plasma arc torch in the glow discharge mode comprisesadjusting the position of the first electrode to be proximate to thefirst end of the hollow electrode nozzle.
 13. The method as recited inclaim 1, wherein the step of operating the multi-mode plasma arc torchin the plasma arc mode comprises adjusting the position of the firstelectrode to be spaced apart from the first end of the hollow electrodenozzle.
 14. The method as recited in claim 1, further comprising asecond electrode disposed outside of the cylindrical vessel proximate tothe second end of the hollow electrode nozzle.
 15. The method as recitedin claim 14, the second electrode aligned with the longitudinal axis ofthe cylindrical vessel and sized to pass through the hollow electrodenozzle and contact the first electrode.
 16. The method as recited inclaim 1, further comprising a third electrode disposed around a portionof the first electrode and having a same polarity as the firstelectrode.
 17. The method as recited in claim 1, further comprising apower supply electrically connected to the first electrode and thehollow electrode nozzle.
 18. The method as recited in claim 1, furthercomprising: a first three-way valve connected to the first tangentialinlet/outlet; and a second three-way valve connected to the secondtangential inlet/outlet.
 19. The method as recited in claim 18, furthercomprising a third three-way valve connected to the second end of thehollow electrode nozzle.
 20. The method as recited in claim 19, furthercomprising a pump/compressor having a discharge connected to the firstthree-way valve and the second three-way valve.
 21. The method asrecited in claim 1, further comprising a cyclone separator, a volute, apump compressor, a filter screen, an ejector, an eductor, a crossconnector, a screw feeder, a valve, a tee connector, an linear actuatorhaving an anode electrode, a wave guide or an RF coil connected to thesecond end of the hollow electrode nozzle.
 22. A method for operating amulti-mode plasma arc torch comprising the steps of: providing a plasmaarc torch comprising a cylindrical vessel having a first end and asecond end, a first tangential inlet/outlet connected to or proximate tothe first end, a second tangential inlet/outlet connected to orproximate to the second end, an electrode housing connected to the firstend of the cylindrical vessel such that a first electrode is (a) alignedwith a longitudinal axis of the cylindrical vessel, and (b) extends intothe cylindrical vessel, a hollow electrode nozzle connected to thesecond end of the cylindrical vessel such that a center line of thehollow electrode nozzle is aligned with the longitudinal axis of thecylindrical vessel, the hollow electrode nozzle having a first enddisposed within the cylindrical vessel and a second end disposed outsidethe cylindrical vessel; providing a pump/compressor; providing a firstthree-way valve connected to the first tangential inlet/outlet and adischarge of the pump/compressor; providing a second three-way valveconnected to the second tangential inlet/outlet and the discharge of thepump/compressor; providing a third three-way valve connected to thesecond end of the hollow electrode nozzle and the discharge of thepump/compressor; and operating the multi-mode plasma arc torch in a deadshort resistive mode, a submerged arc mode, an electrolysis mode, a glowdischarge mode or a plasma arc mode by adjusting a position of the firstelectrode with respect to the hollow electrode.
 23. The method asrecited in claim 22, further comprising a non-conductive granularmaterial disposed between the hollow electrode nozzle and thecylindrical vessel.
 24. The method as recited in claim 22, wherein thenon-conductive granular material comprises marbles, ceramic beads,molecular sieve media, sand, limestone, activated carbon, zeolite,zirconium, alumina, rock salt, nut shell or wood chips.
 25. The methodas recited in claim 22, further comprising a linear actuator operablyconnected to the first electrode to adjust the position of the firstelectrode with respect to the hollow electrode nozzle.
 26. The method asrecited in claim 22, the first end of the cylindrically shaped electrodehaving a first inner diameter that is larger than a second innerdiameter of the second end of the cylindrically shaped electrode nozzle.27. The method as recited in claim 26, the first inner diameter and thesecond inner diameter forming a counterbore.
 28. The method as recitedin claim 26, further comprising a first tapered portion within thecylindrically shaped electrode that transitions from the first innerdiameter to the second inner diameter.
 29. The method as recited inclaim 26, further comprising a second tapered portion within thecylindrically shaped electrode that transitions from the first innerdiameter to a third inner diameter at the first end of the cylindricallyshaped electrode wherein the third inner diameter is larger than thefirst inner diameter.
 30. The method as recited in claim 22, the hollowelectrode nozzle having an external flange.
 31. The method as recited inclaim 22, wherein the step of operating the multi-mode plasma arc torchin the dead short resistive mode comprises adjusting the position of thefirst electrode to contact the hollow electrode nozzle.
 32. The methodas recited in claim 22, wherein the step of operating the multi-modeplasma arc torch in the submerged arc mode comprises adjusting theposition of the first electrode to extend into the hollow electrodenozzle proximate to the second end of the hollow electrode nozzle. 33.The method as recited in claim 22, wherein the step of operating themulti-mode plasma arc torch in the electrolysis mode comprises adjustingthe position of the first electrode to extend into the hollow electrodenozzle proximate to the first end of the hollow electrode nozzle. 34.The method as recited in claim 22, wherein the step of operating themulti-mode plasma arc torch in the glow discharge mode comprisesadjusting the position of the first electrode to be proximate to thefirst end of the hollow electrode nozzle.
 35. The method as recited inclaim 22, wherein the step of operating the multi-mode plasma arc torchin the plasma arc mode comprises adjusting the position of the firstelectrode to be spaced apart from the first end of the hollow electrodenozzle.
 36. The method as recited in claim 22, further comprising athird electrode disposed around a portion of the first electrode andhaving a same polarity as the first electrode.
 37. The method as recitedin claim 22, further comprising a power supply electrically connected tothe first electrode and the hollow electrode nozzle.
 38. A method foroperating a multi-mode plasma arc torch comprising the steps of:providing the multi-mode plasma torch comprising a cylindrical vesselhaving a first end and a second end, a first tangential inlet/outletconnected to or proximate to the first end, a second tangentialinlet/outlet connected to or proximate to the second end, an electrodehousing connected to the first end of the cylindrical vessel, theelectrode housing having a first electrode aligned with a longitudinalaxis of the cylindrical vessel, extending into the cylindrical vessel,moveable along the longitudinal axis, and electrically isolated from thecylindrical vessel, a hollow electrode nozzle connected to the secondend of the cylindrical vessel such that a center line of the hollowelectrode nozzle is aligned with the longitudinal axis of thecylindrical vessel, the hollow electrode nozzle having a first enddisposed within the cylindrical vessel and a second end disposed outsidethe cylindrical vessel, and a linear actuator operably connected to thefirst electrode to adjust a position of the first electrode with respectto the hollow electrode nozzle; and operating the multi-mode plasma arctorch in a dead short resistive mode, a submerged arc mode, anelectrolysis mode, a glow discharge mode or a plasma arc mode byadjusting the position of the first electrode with respect to the hollowelectrode nozzle using the linear actuator.
 39. The method as recited inclaim 38, further comprising a non-conductive granular material disposedbetween the hollow electrode nozzle and the cylindrical vessel.
 40. Themethod as recited in claim 39, wherein the non-conductive granularmaterial comprises marbles, ceramic beads, molecular sieve media, sand,limestone, activated carbon, zeolite, zirconium, alumina, rock salt, nutshell or wood chips.
 41. The method as recited in claim 38, the firstend of the cylindrically shaped electrode having a first inner diameterthat is larger than a second inner diameter of the second end of thecylindrically shaped electrode nozzle.
 42. The method as recited inclaim 41, the first inner diameter and the second inner diameter forminga counterbore.
 43. The method as recited in claim 41, further comprisinga first tapered portion within the cylindrically shaped electrode thattransitions from the first inner diameter to the second inner diameter.44. The method as recited in claim 41, further comprising a secondtapered portion within the cylindrically shaped electrode thattransitions from the first inner diameter to a third inner diameter atthe first end of the cylindrically shaped electrode wherein the thirdinner diameter is larger than the first inner diameter.
 45. The methodas recited in claim 38, the hollow electrode nozzle having an externalflange.
 46. The method as recited in claim 38, wherein the step ofoperating the multi-mode plasma arc torch in the dead short resistivemode comprises adjusting the position of the first electrode to contactthe hollow electrode nozzle.
 47. The method as recited in claim 38,wherein the step of operating the multi-mode plasma arc torch in thesubmerged arc mode comprises adjusting the position of the firstelectrode to extend into the hollow electrode nozzle proximate to thesecond end of the hollow electrode nozzle.
 48. The method as recited inclaim 38, wherein the step of operating the multi-mode plasma arc torchin the electrolysis mode comprises adjusting the position of the firstelectrode to extend into the hollow electrode nozzle proximate to thefirst end of the hollow electrode nozzle.
 49. The method as recited inclaim 38, wherein the step of operating the multi-mode plasma arc torchin the glow discharge mode comprises adjusting the position of the firstelectrode to be proximate to the first end of the hollow electrodenozzle.
 50. The method as recited in claim 38, wherein the step ofoperating the multi-mode plasma arc torch in the plasma arc modecomprises adjusting the position of the first electrode to be spacedapart from the first end of the hollow electrode nozzle.
 51. The methodas recited in claim 38, further comprising a second electrode disposedoutside of the cylindrical vessel proximate to the second end of thehollow electrode nozzle.
 52. The method as recited in claim 51, thesecond electrode aligned with the longitudinal axis of the cylindricalvessel and sized to pass through the hollow electrode nozzle and contactthe first electrode.
 53. The method as recited in claim 38, furthercomprising a third electrode disposed around a portion of the firstelectrode and having a same polarity as the first electrode.
 54. Themethod as recited in claim 38, further comprising a power supplyelectrically connected to the first electrode and the hollow electrodenozzle.
 55. The method as recited in claim 38, further comprising: afirst three-way valve connected to the first tangential inlet/outlet;and a second three-way valve connected to the second tangentialinlet/outlet.
 56. The method as recited in claim 55, further comprisinga third three-way valve connected to the second end of the hollowelectrode nozzle.
 57. The method as recited in claim 55, furthercomprising a pump/compressor having a discharge connected to the firstthree-way valve and the second three-way valve.
 58. The method asrecited in claim 38, further comprising a cyclone separator, a volute, apump compressor, a filter screen, an ejector, an eductor, a crossconnector, a screw feeder, a valve, a tee connector, an linear actuatorhaving an anode electrode, a wave guide or an RF coil connected to thesecond end of the hollow electrode nozzle.